Iron sulphide material and process of making the same



- -l"a.tentecl"Apr, 18, 1933 v a p I' l p 5 CINCINNATI, ofiIo, ASSIGNQRSTo manztronQanSoncoursing,or nooxnaigingoriio, I

- e sro moms I sjupriimn armara: AND raocssse mma l iworrawnianimationmean nfie, iszaf ss'mynoymsm; 1

wour invention irelatesfto the :production Theairfsupplytdour'furnacemayjbe pre of castings containinimironsulphidewhich heated with any waste energy such as is can used with advantage:asoluble obtained from 'the' stackpgases, but that is anode process orforming electrolytic iron non-essentialxandweobtainferroHssuIphide withT progressive maintenance of gamcondi material using a cold air blast,at a temperation of negligible hydrogen ion .iconcentrat'ure-sufficiently above the melting gpointfor tion in the electrolyte.a J proper pouring andcasting. Q ,Itis the objectof our inventiontoprovide We prepare the ores ofhematite and py-f' an anode for thepurpose namediromreadiritein finelyxdivided form, and mi xathem lyobtainable: ores, with the minimum of with reaction coke using a binderwhich Will 139 expense, and "using as littleheat as possible. permit ofbriquettingH-Thishelpsto avoid Specifically it is ourobject to formanodes loss or sulphur-through thestack. i

as bodiescast from material iormed by-heat- In starting a run we:charge; the ingto ether ironioxiclerlhematite vore) i andwitl1-coke,-whichis ignited. )When the shaft iron d zksulphide (pyrite),both :o-;E.- which is hot, the cokelayer is covered with briquets, 65are plentifulrminera'ls. v "1 I -r 1,173.1, thenwith a-further layer'ofcoke, thenlay-. I

Theequipmentrused dus may heacupola 'ers of briquets and cokealternately;

- or shaft fu rnaoewhich iseconomica'l tobuild We get best results- ,byusing unflithe and operate-,-- linedupreferably 'with' refracbriquetsenough of theironpyrite to result 3 tories whichrwillnot be corroded byferrous in a slight exoesslof sulphur .overiiwh'at r sulphide atthemeltingazone,magnesiagora would be. required ito give theexactcomneutral lining suchaslcarbonundum, giving 'bining'weightsm, goodresultspj nweefindthat we get%good-resul=ts,byusing ;Indescribingourprocess-we will give the some; surplus ,reaotion cokejover'the proper best procedure as now ,follovviedlbyus, it combiningweight. Y being "under-stoodthat this is merely indica- We find.'tpreferable to control, the -air tive of onemode oishoppracticewhich'is blast, andto measurewboth the rate Lot-flow -availwblenByiusingla coke-similar' to blast and the pressure thereof; flh'eb1ast;; wil1 fu rnace:coke -wefiobtain furnacenflue gasesvary,otcoursdwiththe .rurnaceqand tl e.

' 30 whichrare valuable fior combustion: and gene fuel, andtheioperator'will find itadvisable 3 V .eration of heat 1 tor annealingand other not to drive the furnace} togthepoint, ,ofprocupola furnaces.close regulation of xairsupply ducing in it .7 a strongly:oxidizing;;atmos1 t Y i'lg;cupo1a foundryscoke we .maynalso ebphere,; asthi'spromotes loss ofgisulphur as tain a :combustible'flue gas; a r S0ingthe flue gases- We have, been able A speoial tuel is notrrequiredinour proto control .loss of sulphur through control 3 'cess; and itshouldbe noted thata oonsiderflof the blast. a i v H by able propotion of theirongbearing =con- Theexpendrtureof'heat to makegagiven stituents of 4mcharge do not require charge ofironas iron-sulphide is theoretical-vreduction to iron. Also, the reaction which ly'aboutjfitty percent otwhat would "be re is induced where one atom of Fe, obtained quired,tosproducean equivalent weight of f from reduction of the hematite ore,commolten pig iron, because onlyabout 50%;,of bines with one of theatoms of sulphur in the total iron! inbthe 1 iurnacerequires irethepyrite (Fes giving two molecules of duction; 1 a Q FeS, produces adefinite amount of exother- The iurnace may have agfloorgofltorin micheat, which assists in making the melt stance, molding 33nd,; upon whichwill colT and maintaining thetemperature of the relect ma"thin-'iron-silicate-sulphide1,awskin;

action products above the melting point. Abovethis skin thelmolten FeSwill collect. V I d The resulting molten iron sulphide can be Further,we;:may=secur'e,;moltenimmateriali tapped either into molds or into 'aladle which is essentially alsoli dsolution oiiron from which the moldsarefilled. oxides and iron sulphides, andqthis mate 1 9 cast withterminal rods of iron in them,if

desired.

By crushing the ores and coke to 20mesh size, we obtain a goodyield;WVith a fu nace lining of magnesia refractory we have but little cuttingof the furnace walls, and the slag is easily handled.

As a flux we may use fiuor-sp ar by itself or together with fluxingmaterials of low cost. Using'fluor-spar by itself, the sulphur in theslag isbelow one per cent,-while with ordinary calcium carbonatelimestone by itself the slag contains large proportions of sulphur.

The slag floats upon-the molten. ferrous sulphide in the well of thefurnace and is tapped off.

The product of our invention so far as its physical properties areconcerned is improved considerably as a cast body by a suitable heattreatment and Sampson W. Yates, one of the co-inventors herein is makingapplication for patent of even date herewith for heat control andtreatment of our procluct, and the resultant improved product therebyobtained by him.

When used as anode material, in a ferrous chloride electr0lyte,the castproducts of our process inhibit the formation of ferric salts byelectrolytic action, and thus avoid the formation of acids and thedevelopment of harmful hydrogen ion concentration. They further tenddirectlyto neutralize any acid present. The anodes hold their shape asthey are dissolved and. re-

quire very little cleaning. I

Having thus described our process and product, what we claim as newanddesire to secure by Letters Patent, is

v 1. That process of producing'iron sulphide material, which consists inheating iron ore andpyrite together with a separate reducing agent foriron ore in the presence of burning fuel, with the result of the iron insaid ore taking on an atom-of sulphur,

thus converting the mass mainly into'iron sulphide, the temperature ofthe heating being sufiicient to fuse the iron sulphide and any slagformed and then tapping oil the molten material. i

2. That process of producing iron sulphide material, which consists informing briquets of finely divided iron ore, pyrite and carbon, heatingsaid briquets in a shaft furnace, in the presence of burning fuel andtapping off the resultant material which is mainly iron sulphide thetemperature of the heating being sufficient to fuse the iron sulphidematerial.

1,904,915 r T f mainl iron sul hide and usin a flux in 4 J the processof a type which will'not take-up' sulphur or'iron. P trA processforproducing ferrous sulphide material, which consistsin placing iron ore,pyrite and carbon," together with fuel and flux inashaft furnace,heatingthe products using a blast regulated to oxidize a minimum ofsulphur,'with the; result 0f the formation of molten] ferrous-sulphidematerial the. temperature of theheatin'g being sufficient to fusetheferrous sulphide material; and flowing the'molten material into molds. y

5. A process for producing ferrous sulphide material'which consists incausing oxide iron ore, pyrites and carbon to react together in thepresence of burning fuel to produce molten ferrous sulphide materialandaslag. V p 6. A process for producing, ferrous sul,- phidematerialwhich comprises .comminut-f ing and'mixing a material containingferric sulphide, a material containing a reducible compound of iron anda carbonaceous reducing agent, and heating the mixed materials in thepresence of. burning, solid carbonaceous fuel to a temperaturesuflicienttomelt of iron, and a carbonaceous material," and chargingsaid material withflux comprising fiuorspar intowa furnace, and heatingsaid substancesin the presence of. burning fuel to a temperaturesufficient to fuse the prod ucts of reaction, andseparating theresulting fused ferrous sulphite material from the fused slag.

JOHN R. GAIN. SAMPSON w. YATES.

